Ergonomic mattress carrier

ABSTRACT

A mattress carrier ( 1 ) comprising a base structure ( 2 ) to which compressible means can be attached directly or indirectly, wherein the base structure ( 2 ) comprises an opening ( 3, 11 ) and wherein said mattress carrier ( 1 ) comprises a panel ( 4, 5 ) which can be moved through the opening ( 3, 11 ) and to which compressible means can be attached directly or indirectly, wherein said panel ( 4, 5 ) is movable between a top position in which said panel ( 4, 5 ) extends in a plane located above the plane of the base structure ( 2 ), and a bottom position in which said panel ( 4, 5 ) extends in a plane located below the plane of the base structure ( 2 ).

The present application claims priority from Belgian Patent Application No. BE-2015/5723 filed on Nov. 6, 2015, which is incorporated herein by reference.

FIELD OF THE DISCLOSURE

The disclosure concerns firstly a mattress carrier comprising a base structure to which compressible means can be attached directly or indirectly. Secondly, the disclosure concerns a module suitable for being attached to a base structure, base plate or base plate part, which is provided for adjusting the hardness of the overlying structure.

Furthermore the disclosure concerns a bed assembly comprising a mattress and a mattress carrier provided with a base structure to which springs can be attached directly or indirectly.

The disclosure concerns in particular a box spring mattress carrier and a module which is specifically suitable for being integrated in a box spring bed assembly.

BACKGROUND

A box spring bed assembly is generally known. It is usually constructed from a frame provided with a mattress carrier to which (coil) springs or pocket springs are attached. The actual mattress on which the user lies is laid on this mattress carrier. The mattress carrier serves to support the mattress and ensures increased comfort.

For good quality sleep, one of the basic requirements is the right hardness of the mattress; this must not be too hard but also not too soft. The hardness is a combination of the hardness of the mattress and the hardness of the mattress carrier. Embodiments of this invention relate to the adjustment of the hardness and/or the level of support of the mattress carrier.

However, because different people often prefer a different hardness, and also because the different body parts such as e.g. the head, shoulders, hips etc. require different support, mattress carriers are already known which allow the hardness to be adjusted in certain zones. Thus American patent publication U.S. Pat. No. 3,340,548 discloses a box spring mattress carrier wherein the springs in a specific zone are provided on support plates which are situated at varying heights.

The height of the support plates is adjustable via rotatable elements provided under the support plates.

Another solution for adjusting the hardness in different zones is described in European patent publication EP 2 762 042. This publication describes a bed assembly with a carrier structure arranged below a pocket spring mattress. The carrier structure comprises a flexible elongate element arranged between two fixing elements which are situated on either side of a variable region. Furthermore, a retraction device is provided which can bring the flexible element under tension. The hardness can be adjusted by bringing the flexible element under varying tension levels.

The known solutions are however complex, costly and awkward to implement.

SUMMARY

Embodiments of the invention therefore have an object of creating a mattress carrier which allows the springing capacity and/or extent of support thereof to be adjusted in a simple manner in one or more specific zones, so that the spinal column of a user in any situation lies perfectly straight. The mattress carrier is also not a complex system, so it can be manufactured easily.

This object may be achieved by the provision of the mattress carrier comprising a base structure to which compressible means can be attached directly or indirectly, wherein the base structure comprises an opening and said mattress carrier comprises a panel which can be moved through the opening and to which compressible means can be attached directly or indirectly, wherein said panel is movable between a top position in which said panel extends in a plane located above the plane of the base structure, and a bottom position in which said panel extends in a plane located below the plane of the base structure. By moving the panel upward or downward, the compressible means attached to or lying against the panel are compressed to a greater or lesser extent, or have less support. In this way, the tension in the compressible means can be adjusted and hence the hardness and/or amount of support of the mattress lying thereon can be adjusted in the zone delimited by the panel.

The compressible means are preferably formed by springs or pocket springs. Evidently, other types of springs or other types of compressible materials may be considered, such as e.g. latex, foamed material (with or without a gel layer) etc.

The base structure is preferably configured as a base plate. However, in alternative embodiments, slatted bases, steel structures, or spiral bases may also be used as the base structure.

In a preferred embodiment, the mattress carrier according to the invention comprises a second opening for a second panel which can be moved through this opening and to which compressible means can be attached directly or indirectly, wherein said second panel is also movable between a top position in which said second panel extends in a plane located above the plane of the base structure, and a bottom position in which said second panel extends in a plane located below the plane of the base structure. In this way, a mattress carrier is obtained with a first and second zone in which the hardness and/or extent of support can be adjusted. The zones concerned are situated respectively preferably at the level of the shoulder and the pelvis of the user. The two panels may be moved independently of each other. Evidently, the mattress carrier according to embodiments of the invention may be extended further with a similar third movable panel.

According to a more preferred embodiment of the mattress carrier according to the invention, the panel is movable in a direction perpendicular to the plane of the base structure.

In a particular embodiment of the mattress carrier, the distance between the bottom position and the top position is between 60 and 120 mm. Said distance is preferably 100 mm. In particular, when the movable panel extends in the same plane as the base structure, the movable panel is in its starting position. From this position, the compressible means at the level of the movable panel, in the case where they are in unloaded state, may be more compressed or less supported by moving the panel concerned respectively upward or downward. By an upward movement of the panel, the (unloaded) compressible means (e.g. springs) are brought under compression and become harder. By the downward movement of the panel, the (unloaded) compressible means (e.g. springs) are less supported, whereby at this point effectively a depression is formed. By, for example, creating this depression specifically at the level of the pelvis, it can be ensured that the body of the user lies perfectly straight. In an alternative embodiment, compressible means may be provided which are already partly under compression (loaded) in the starting position. In this case, the compressible means become less hard when the panel is lowered.

The distance which the panel can move upward or downward is preferably half the distance between the bottom and the top position, whereby the panel can be moved over the same distance upward and downward. So from its starting (middle) position, a panel can be moved 50 mm upward and 50 mm downward if the distance between the bottom and top positions is 100 mm. This distance need not however be the same, so in an alternative embodiment the panel may be moved over a different distance upward and downward. Thus from its starting position, a panel may be move 60 mm upward and 40 mm downward if the distance between the bottom and top positions is 100 mm.

In a more particular embodiment of the mattress carrier, the mattress carrier comprises positioning means provided to position the panel in the bottom position, the top position or a position located between the bottom and the top positions. The positioning means preferably comprise two scissor devices supported on a subframe, which each can be extended and retracted by means of a drive mechanism. To be able to move the panel up and down perfectly horizontally, the scissor devices are preferably provided at a distance from each other against the underside of the panel. Because the two scissor devices are driven by the same drive mechanism, preferably a linear motor, the stability of the panel during the upward and downward movement is ensured. Other preferred drive mechanisms are stepper motors, stepper motors with a trapezoid spindle, a drive mechanism with a rod or trolleys which can move to and fro, etc.

To secure the positioning means against the base structure of the mattress carrier, in a preferred embodiment the base structure comprises two or more fixing brackets placed at a distance from each other and each suitable for receiving one end of the subframe of a scissor device.

According to a most preferred embodiment of the mattress carrier according to the invention, the base structure is a base plate constructed from several base plate parts which are connected pivotably together, wherein one or more base plate parts comprises an opening for a movable panel. Preferably, the mattress carrier furthermore comprises electric means which allow one or more base plate parts to move automatically relative to each other.

Another object of embodiments of the invention is a module suitable for being attached to a base structure, base plate or base plate part and which is provided for setting the hardness and/or level of support of the overlying structure, wherein the module comprises a movable panel to which compressible means can be attached directly or indirectly, wherein said panel is movable between a top position in which said panel, in the fixed state of the module, extends in a plane located above the plane of the base structure, base plate or base plate part, and a bottom position in which said panel, in the fixed state of the module, extends in a plane located below the plane of the base structure, base plate or base plate part. Such a module has the advantage that it can easily be fitted.

Such a module has the advantage that it can also be integrated in existing systems, such as e.g. a box spring. It can also for example be integrated in a sofa-bed type furniture.

In a preferred embodiment, the module comprises positioning means provided to position the panel in the bottom position, the top position or a position located between the bottom and the top positions. Preferably, the positioning means comprise two scissor devices supported on a subframe, which can each be extended and retracted by means of a drive mechanism, in particular a linear motor. Also, other drive mechanisms as indicated above may be used.

In a more preferred embodiment of the module according to the invention, the module comprises fixing brackets provided to receive one end of the subframe.

In the module too, the compressible means are preferably formed by springs or pocket springs. Evidently, other types of spring or other forms of compressible material e.g. latex, foamed material (with or without a gel layer) etc. may be considered.

A further object of embodiments of the invention concerns a bed assembly comprising a mattress and mattress carrier provided with a base structure to which compressible means can be attached directly or indirectly, wherein the base structure comprises an opening and said mattress carrier comprises a panel which can be moved through the opening and to which compressible means can be attached directly or indirectly, wherein said panel is movable between a top position in which said panel extends in a plane located above the plane of the base structure, and a bottom position in which said panel extends in a plane located below the plane of the base structure.

The mattress of the bed assembly preferably comprises a mattress core provided with coil springs, pocket springs, foam, latex, visco-gel, natural materials or a combination thereof.

In a preferred embodiment of the bed assembly according to the invention, the compressible means are springs or pocket springs which are attached directly or indirectly to the movable panel and protected by a protective layer, such that said springs cannot protrude above the top plane of the mattress carrier when the panel is in its top position. The protective layer is preferably a material with little stretch capacity, such as e.g. polyester (100%).

The bed assembly according to embodiments of the invention is preferably a box spring.

In particular, the mattress carrier of the bed assembly according to embodiments of the invention is manufactured as described above.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be explained in more detail with reference to the following detailed description of a mattress carrier and module according to the invention. The aim of this description is exclusively to give a clarifying example and to indicate further advantages and features of the invention, and it may not therefore be interpreted as a restriction of the area of application of the invention or of the rights claimed in the claims.

In this detailed description, by means of reference numerals, reference is made to the enclosed drawings in which:

FIG. 1 is a top view of a mattress carrier according to an embodiment of the invention with two movable panels which are in the starting position;

FIG. 2 is a top view of a mattress carrier according to an embodiment of the invention comprising two movable panels, with one panel in its bottom position and the second panel in its top position;

FIG. 3 is a bottom view of the mattress carrier depicted in FIG. 2;

FIG. 4 is a perspective depiction of a module according to an embodiment of the invention in retracted state and suitable for being attached to a base structure, a base plate or a base plate part;

FIG. 5 is a perspective depiction of the module shown in FIG. 4 in extended state;

FIG. 6 shows a cross section of the mattress carrier according to an embodiment of the invention;

FIG. 7 is a bottom view of a mattress carrier according to an embodiment of the invention comprising two movable panels and provided with an alternative module;

FIG. 8 is a perspective depiction of the module according to the invention shown in FIG. 7 in retracted state and suitable for being attached to a base structure, a base plate or base plate part;

FIG. 9 is a perspective depiction of the module shown in FIG. 8 in extended state.

DETAILED DESCRIPTION OF EMBODIMENTS

FIG. 1 shows a possible embodiment of a mattress carrier (1) according to the invention. Such a mattress carrier (1) serves to support a mattress on which a user will rest, and ensures increased comfort.

The mattress carrier (1) shown comprises a base structure (2) in the form of a plate-like material (base plate) to which compressible means (not shown), such as for example springs (coil or pocket springs), a foamed material, visco-elastic material etc. can be attached directly or indirectly. The base plate (2) is produced as standard from wood and has a thickness of between 5 and 35 mm. The length of the base plate in practice is between 175 and 245 cm.

In the zones where the hardness and/or level of support of the mattress is to be adjusted, an opening (3, 11) is provided in the base plate (2), for example by cutting. In the embodiment shown, two openings (3 and 11) are provided. In this way, an adjustable hardness zone (support zone) is created at the level of the shoulders and an adjustable hardness zone (support zone) at the level of the pelvis of a user.

The openings made (3, 11) in practice have a length of between 25 and 60 cm, and a width of between 50 and 130 cm. A panel (4, 5) can be moved through the respective opening (3, 11). This panel (4, 5) is in practice formed by the piece cut out from the base plate (2). To avoid catching, the corners of the cut-out piece may be rounded and a zone of around 1 mm is left clear between the peripheral edges of the opening (3, 11) and the panel (4, 5). Compressible means, e.g. springs, can also be attached directly or indirectly to the panel (4, 5).

The panels (4, 5) are movable between a top position in which the panel (4, 5) extends in a plane located above the plane of the base plate (2), and a bottom position in which said panel (4, 5) extends in a plane located below the plane of the base plate (2). In FIG. 2, the first panel (4) is its bottom position while the second panel (5) is in its top position.

The distance between the bottom position and the top position is between 60 and 120 mm. Said distance is preferably 100 mm. When a movable panel (4, 5) extends in the same plane as the base plate (2), as shown on FIG. 1, the respective panel (4, 5) is in its starting position. From this position, the compressible means which are attached directly or indirectly to the movable panel, depending on their present state, may be compressed to a greater or lesser extent, or less compressed or less supported, by moving the respective panel (4, 5) upward or downward. The distance over which the panel (4, 5) can move upward or downward is normally half the distance between the bottom and the top positions. Thus a panel (4, 5) can move from its middle position 50 mm upward and 50 mm downward if the distance between the top and bottom positions is 100 mm. Evidently, other embodiments are possible in which the distance over which a panel moves upward is not the same as the distance over which a panel (4, 5) moves downward.

To position the panel (4, 5) in the bottom position, the top position or a position located between the bottom and top positions, the mattress carrier (1) is provided with positioning means (6). These positioning means (6) preferably comprise two scissor devices (8 a and 8 b) supported on a subframe, which can each be extended and retracted by means of a drive mechanism (9), such as for example a linear motor. In FIG. 4, the two scissor devices (8 a, 8 b) are in the retracted position. The drive mechanism (9) is configured such that the scissor device can be extended (see FIG. 5) by moving two associated ends of the scissor legs towards each other.

To move the panel (4, 5) upward and downward perfectly horizontally, the scissor devices (8 a, 8 b)—as shown in FIG. 3—are preferably provided spaced apart from each other against the underside of the panel (4, 5). Because the two scissor devices (8 a, 8 b) are driven by the same drive mechanism (9), preferably a linear motor, the stability of the panel (4, 5) during the upward and downward movement is ensured.

Such positioning elements (6) are provided for each panel (4, 5). In this way the panels (4, 5) can move independently of each other.

The positioning means (6) are fixed against the base plate (2) of the mattress carrier (1) by means of fixing brackets (10). In the figures shown, two fixing brackets (10) are used placed at a distance apart, each of which receives one end of both subframes (7) of a scissor device (8 a, 8 b). Evidently instead of two, four fixing brackets (10) may be used wherein then each end is attached to the base plate (2) via a separate bracket (10).

By moving the panels (4, 5) upward or downward, the compressible means (e.g. springs) which are attached to or lie against this panel are compressed (or supported) to a greater or lesser extent. In this way, the tension in the compressible means or springs, and hence the hardness or level of support of the overlying mattress, can be adjusted in the zone which is delimited by the panel (4, 5).

The advantage of such a mattress carrier (1) is that it can be adapted to the wishes of the user, who can move the first (4) and second panel (5) up and down to adjust the hardness at the level of the shoulder and pelvic zone as he wishes.

The system described above may be provided in a separate module (12) (as shown in FIGS. 4 and 5). One or more such modules (12) may then be attached for example to the underside of a base structure, base plate (2) or base plate part of a box spring or other bed. Evidently, the necessary openings (3, 11) for the panels (4, 5) and space for the positioning means must be present or arranged thereon.

Such a module (12) comprises a movable panel (4, 5) to which springs or other compressible means can be attached directly or indirectly. The panel (4, 5) can be moved between a top position in which said panel (4, 5) extends in a plane located above the plane of the base plate, and a bottom position in which said panel extends in a plane located below the plane of the base plate. The positioning means as described above also form part of the module (12).

Thanks to the use of such modules (12), the production of mattress carriers (1), which allow adjustment of the hardness or support in specific zones of the mattress, is extremely simple. It is only necessary to provide the openings (3, 11) and attach the module (12) at the correct point.

FIGS. 7 to 9 show an alternative module. The difference from the module described above is that here an extruded profile is used, which is provided with a guide groove in which the ends of the scissor legs are mounted displaceably via a guide element, preferably made of plastic. In this way, the scissor legs can easily be moved in a direction towards or away from each other.

The mattress carrier (1) according to this invention and as shown on the attached figures forms part of a bed assembly, preferably this may be a box spring assembly. With such an assembly, a mattress—and in some cases also a top mattress—is placed on the mattress carrier (1). The mattress concerned is preferably a mattress in which the mattress core comprises pocket springs or coil springs. Evidently, mattresses may also be used in which the mattress core comprises latex, natural materials, cold foam, visco-elastic materials (e.g. gel), or combinations of these materials.

Because of the movable panels (4, 5), zones with adjustable hardness and/or support are created in the mattress. The size of the zones is determined by the size of the panels (4, 5). Changing the hardness and/or support in the mattress is extremely simple and takes place by moving the panels (4, 5) provided in the mattress carrier (1) either upward or downward from the starting position, in order in this way e.g. to increase or reduce the hardness in a specific zone. 

1. Mattress carrier comprising a base structure to which compressible material can be attached directly or indirectly, wherein the base structure comprises an opening and said mattress carrier comprises a panel which can be moved through the opening and to which compressible material can be attached directly or indirectly, wherein said panel is movable between a top position in which said panel extends in a plane located above the plane of the base structure, and a bottom position in which said panel extends in a plane located below the plane of the base structure.
 2. Mattress carrier according to claim 1, characterized in that the panel is movable in a direction perpendicular to the plane of the base structure.
 3. Mattress carrier according to claim 1, characterized in that the distance between the bottom position and the top position is between 60 and 120 mm.
 4. Mattress carrier according to claim 1, characterized in that the mattress carrier comprises positioners provided to position the panel in the bottom position, the top position or a position located between the bottom and the top positions.
 5. Mattress carrier according to claim 4, characterized in that the positioners comprise two scissor devices supported on a subframe which can each be extended and retracted by means of a drive mechanism.
 6. Mattress carrier according to claim 5, characterized in that the base structure comprises two or more fixing brackets placed at a distance from each other and each suitable for receiving one end of the subframe of a scissor device.
 7. Mattress carrier according to claim 5, characterized in that the drive mechanism comprises a linear motor.
 8. Mattress carrier according to claim 1, characterized in that the base structure has a second opening and that said mattress carrier comprises a second panel which can be moved through this opening and to which the compressible material can be attached directly or indirectly, wherein said second panel is movable between a top position in which said second panel extends in a plane located above the plane of the base structure, and a bottom position in which said second panel extends in a plane located below the plane of the base structure.
 9. Mattress carrier according to claim 1, characterized in that the base structure is a base plate.
 10. Mattress carrier according to claim 9, characterized in that the base plate is constructed from several base plate parts which are connected pivotably together, wherein one or more base plate parts comprises an opening for a movable panel.
 11. Mattress carrier according to claim 1, characterized in that the compressible material is springs, pocket springs and/or foamed material, or latex or a latex gel combination, or a foam gel combination.
 12. Module which is suitable for being attached to a base structure, base plate or base plate part and which is provided for setting the hardness and/or level of support of the overlying structure, wherein the module comprises a movable panel to which compressible material can be attached directly or indirectly, wherein said panel is movable between a top position in which said panel, in the fixed state of the module, extends in a plane located above the plane of the base structure, base plate or base plate part, and a bottom position in which said panel, in the fixed state of the module, extends in a plane located below the plane of the base structure, base plate or base plate part.
 13. Module according to claim 12, characterized in that the module comprises positioners provided to position the panel in the bottom position, the top position or a position located between the bottom and the top positions.
 14. Module (12) according to claim 12, characterized in that the positioners comprise two scissor devices supported on a subframe which can each be extended and retracted by means of a drive mechanism.
 15. Module according to claim 14, characterized in that the drive mechanism comprises a linear motor.
 16. Module according to claim 12, characterized in that the module comprises fixing brackets provided to receive one end of the subframe. 